U.S. patent number 9,420,074 [Application Number 14/271,374] was granted by the patent office on 2016-08-16 for light guided alignment for semi-automated seal application.
This patent grant is currently assigned to Apple Inc.. The grantee listed for this patent is Apple Inc.. Invention is credited to Colin M. Ely, David Glenn Havskjold, Tyson Benner Manullang, Emery A. Sanford.
United States Patent |
9,420,074 |
Ely , et al. |
August 16, 2016 |
Light guided alignment for semi-automated seal application
Abstract
In one embodiment, a method of installing a component in an
electronic device is described. A light source shines a light
through an aperture of on one end of the electronic device. A light
sensor positioned on the opposite end moves with a fixture having
the component. When the light sensor determines a central portion
of the light, the fixture and the component may be aligned with the
aperture of the electronic device, and the fixture installs the
component. In another embodiment, a method of detecting proper
installment of the component is described. A microphone may be used
to detect sound transmission from a speaker which transmits sound
through the aperture. If the microphone detects sounds from an
interface region between the component and the housing, the
component is not properly installed.
Inventors: |
Ely; Colin M. (Cupertino,
CA), Havskjold; David Glenn (Portola Valley, CA),
Sanford; Emery A. (San Francisco, CA), Manullang; Tyson
Benner (Sunnyvale, CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Apple Inc. |
Cupertino |
CA |
US |
|
|
Assignee: |
Apple Inc. (Cupertino,
CA)
|
Family
ID: |
54369136 |
Appl.
No.: |
14/271,374 |
Filed: |
May 6, 2014 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20150327412 A1 |
Nov 12, 2015 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H04M
1/026 (20130101); H05K 13/0015 (20130101); H04M
1/24 (20130101); Y10T 29/53265 (20150115); Y10T
29/49897 (20150115); H04M 2250/12 (20130101) |
Current International
Class: |
H05K
13/00 (20060101); H04M 1/02 (20060101); H04M
1/24 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Bryant; David
Assistant Examiner: Yoo; Jun
Attorney, Agent or Firm: Downey Brand LLP
Claims
What is claimed is:
1. A method for aligning and installing a component with an
electronic device having a housing that includes a housing
aperture, the method comprising: securing the component with a
fixture, the component comprising a component aperture; providing,
from a light source, light having a maximum intensity that passes
through the housing aperture and the component aperture to a light
sensor carried by the fixture, the maximum intensity associated
with a central portion of the light; actuating the fixture
perpendicular with respect to the light such that the light sensor
detects the maximum intensity; and actuating the fixture toward the
housing to secure the component with the housing.
2. The method as recited in claim 1, wherein the light source is
external with respect to the housing.
3. The method as recited in claim 1, further comprising: detecting,
with the light sensor, a first intensity of the light less than the
maximum intensity at a first portion of the light, the first
portion different from the central portion; detecting, with the
light sensor, a second intensity of the light less than the maximum
intensity at a second portion of the light with the light sensor,
the second portion different from the central portion; and
determining the maximum intensity based on the first intensity and
the second intensity.
4. The method as recited in claim 1, wherein providing, from the
light source, the light comprises providing the light that passes
through a mesh portion of the component.
5. The method as recited in claim 1, wherein the fixture includes a
chamber defining an opening of the fixture.
6. The method as recited in claim 5, wherein the light sensor is
positioned within the chamber.
7. The method as recited in claim 5, wherein the opening of the
fixture is similar to the component aperture.
8. The method as recited in claim 1, wherein securing the component
with the housing comprises: adhesively attaching the component to
an interior region of the housing such that the housing aperture is
aligned with the component aperture.
9. The method as recited in claim 8, further comprising, subsequent
to the adhesively attaching the component, performing a test to
determine an alignment of the component on the housing.
10. The method as recited in claim 1, wherein actuating the fixture
comprises: actuating the fixture in accordance with a first
direction to determine a first plurality of light intensities;
actuating the fixture in accordance with a second direction to
determine a second plurality of light intensities different from
the first plurality of light intensities; and determining the
maximum intensities based on the first plurality of intensities and
the second plurality of intensities.
11. The method as recited in claim 10, wherein the first direction
is perpendicular with respect to the second direction.
12. The method as recited in claim 10, wherein securing the
component with the housing comprises acoustically sealing the
component with the housing.
Description
FIELD
The described embodiments relate generally to installing a
component to a device. In particular, the present embodiments
relate to aligning the component with an inner portion of an
electronic device for installation of the component, and testing to
ensure proper installation of the component once installed.
BACKGROUND
Proper installment of components in an electronic device generally
leads to better overall performance of the electronic device. In
order to properly install components in several electronic devices
on an assembly line, it may be necessary to automate the process.
One automation process includes a camera system having a
charge-coupled device ("CCD") camera or a complementary metal-oxide
semiconductor ("CMOS") camera used in conjunction with a software
package configured to detect placement of components on the
electronic device. The camera system may, for example, capture an
image of the component on the electronic device and use the
software package to compare the image with an image of a properly
installed component.
However, camera systems are relatively expensive. In addition,
several manual hours may be required to operate the camera system.
For example, an operator must be properly trained on how the camera
system works. Also, the camera systems may require proper alignment
at all times which may be difficult in an assembly line.
Realignment may also cost several manual hours. Also, variations in
lighting within the assembly line may reduce the ability for the
camera system to function in the desired manner.
SUMMARY
In one aspect, a method for aligning a component for installation
in a housing of an electronic device is described. The method may
include shining a light from a light source through an aperture of
the housing, the light having a central portion. The method may
also include actuating a fixture, the fixture having the component
and a light sensor, along a first direction such that the light
sensor detects the light. The method may also include aligning the
light sensor with the central portion of the light.
In another aspect, a method for testing for proper installation of
a component to a housing of an electronic device is described. The
method may include transmitting a sound through an aperture of the
housing, the sound originating from an outer portion of the
housing. The method may also include transmitting the sound through
an aperture of the component and a chamber of a fixture. The
fixture is sealed to the component. The method may also include
determining whether a portion of the sound is detected in an area
proximate to an interface region of the housing and the
component.
In another aspect, a fixture on an assembly line for manufacturing
an electronic device is described. The fixture may include a first
portion having a first cavity; the first cavity extending to a
first opening on a surface of the first portion. The fixture may
also include a second portion having a second cavity extending from
a second opening on a second surface of the fixture to a third
opening on a third surface of the fixture; the second cavity is
substantially perpendicular to the first cavity and configured to
receive a protrusion. The first cavity may include a cross
sectional area substantially similar to a cross sectional area of
an aperture of a component to be installed on the electronic
device, and the fixture may be capable of rotating around a
longitudinal axis of the protrusion.
A fixture on an assembly line for manufacturing an electronic
device is described. The fixture may include a first cavity
extending to a first opening on a first surface of the fixture. The
fixture may also include a second cavity extending from a second
opening on a second surface of the fixture to a third opening on a
third surface of the fixture. The second cavity is capable of
receiving a protrusion that actuates the fixture. The first cavity
is smaller than an aperture of a component, the component
configured to be installed on the electronic device. The fixture is
capable of rotating about a longitudinal axis of the protrusion
when the second cavity receives the protrusion.
Other systems, methods, features and advantages of the embodiments
will be, or will become, apparent to one of ordinary skill in the
art upon examination of the following figures and detailed
description. It is intended that all such additional systems,
methods, features and advantages be included within this
description and this summary, be within the scope of the
embodiments, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will be readily understood by the following detailed
description in conjunction with the accompanying drawings, wherein
like reference numerals designate like structural elements, and in
which:
FIG. 1 shows an isometric view of an embodiment of a system used to
align a component in an electronic device;
FIG. 2 shows an exploded view of an embodiment of a component near
an embodiment of a housing of the electronic device;
FIG. 3 shows a dimensional comparison of an aperture in the
embodiment of the component and an aperture in the embodiment of
the housing, both of which are shown in FIG. 2;
FIG. 4 shows a cross sectional view of the embodiment of the system
shown in FIG. 1 with a light source shining light into the
housing;
FIG. 5 shows a cross sectional cutaway along the 5-5 line in FIG. 4
showing an embodiment of a light gradient created by the light
source;
FIGS. 6-9 show an embodiment of the light sensor, fixture, and
component traversing in the y-direction to find the central portion
(or local maximum) of the light source;
FIG. 10 shows a flow chart of an alignment process in accordance
with the described embodiments;
FIG. 11 shows a top view of an embodiment of a fixture;
FIG. 12 shows an isometric view of an embodiment of a system used
to test for proper installment of a component in an electronic
device;
FIG. 13 shows a cross sectional view of the embodiment of the
system shown in FIG. 12 with an audio speaker emitting sound into a
chamber of a fixture;
FIGS. 14 and 15 show cross sectional views of improper alignment of
a component on an electronic device;
FIG. 16 shows an alternate embodiment of a system used to test for
proper installment of a component in an electronic device; and
FIG. 17 shows a flow chart of a testing process in accordance with
the described embodiments.
Those skilled in the art will appreciate and understand that,
according to common practice, various features of the drawings
discussed below are not necessarily drawn to scale, and that
dimensions of various features and elements of the drawings may be
expanded or reduced to more clearly illustrate the embodiments of
the present invention described herein.
DETAILED DESCRIPTION
Reference will now be made in detail to representative embodiments
illustrated in the accompanying drawings. It should be understood
that the following descriptions are not intended to limit the
embodiments to one preferred embodiment. To the contrary, it is
intended to cover alternatives, modifications, and equivalents as
can be included within the spirit and scope of the described
embodiments as defined by the appended claims.
In the following detailed description, references are made to the
accompanying drawings, which form a part of the description and in
which are shown, by way of illustration, specific embodiments in
accordance with the described embodiments. Although these
embodiments are described in sufficient detail to enable one
skilled in the art to practice the described embodiments, it is
understood that these examples are not limiting; such that other
embodiments may be used, and changes may be made without departing
from the spirit and scope of the described embodiments.
The following disclosure relates to aligning a component within a
device (e.g., a tablet computer, portable electronic device) during
an assembly process, as well as testing to ensure the component is
properly installed. The component may include an acoustic seal. In
one embodiment, the assembly process may include a fixture attached
to a movable table, both of which are proximate to an inner portion
of a housing of the device. The fixture may be configured to rotate
at least partially around an axis. A light sensor may also be
positioned within a chamber of the fixture. The component and a
release layer may also be positioned on an outer surface of the
fixture. Light from a light source passes through an aperture of
the housing of the device to the light sensor. The movable table
may move the fixture in multiple directions allowing the light
sensor to determine the area of highest light intensity ("local
maximum") of the light source. The light source is positioned such
that the local maximum extends through a central portion of the
aperture of the housing. Using information from the light sensor,
the movable table may move the fixture, and accordingly, the
component, to the local maximum. The fixture may then move in a
direction toward the inner surface to install the component.
In another embodiment, an acoustical test ensures a component is
properly installed. The component is attached to an inner surface
of a housing of a device, and configured to extend around an
aperture of the housing. A pressure sensitive adhesive ("PSA") may
be used to attach the component to the housing. An audio speaker is
placed on an outer portion of the housing. A microphone may be
attached to a fixture substantially similar to the fixture
previously described. The acoustical test may be performed by
emitting sound from the audio speaker and through the aperture of
the housing, an aperture of the component, and into a chamber of
the fixture. If the microphone does not detect the emitted sound,
the component is properly installed. If the microphone detects the
emitted sound, the component is not properly installed. The
acoustical test is generally performed during early stages of the
assembly. Thus, if improper installation is detected, the housing
may be discarded from the assembly process with minimal assembly
rather discarding a fully assembled device. Also, this combined
test and assembly step is at least one less step used to assemble
the device which may contribute to lower manufacturing time and
cost.
For purposes of clarity, the term "longitudinal" as used throughout
this detailed description and in the claims refers to a direction
extending a length or major axis of a component. Also, the phrase
"acoustically sealed" as used throughout this detailed description
and in the claims refers to two structures engaged with one another
such that sound cannot pass through a portion where the two
structures are engaged.
FIGS. 1-4 illustrate a portion of an assembly station for
assembling device 100. The device 100 may be a device such as a
tablet computer, mobile telecommunications device (for example,
smartphone), or portable laptop computer. FIG. 1 shows an isometric
view of the assembly station having fixture 110 configured to
attach a component to housing 101 of the device. The component may
be an acoustic seal configured to prohibit dust or other
contaminants from entering an aperture of device 100. Generally,
fixture 110 may be any structure used in an assembly process
capable of affixing small components to a device 100. In some
embodiments, the component may be a button. In the embodiment shown
in FIG. 1, fixture 110 is configured to install a component, or
microphone seal (discussed later). Also, in some embodiments,
fixture 110 may be made of plastic, metal, or a combination
thereof. In the embodiment shown in FIG. 1, fixture 110 is made of
aluminum. Also, fixture 110 is generally "L-shaped" but could be
any shape in order to achieve a desired result, such align and
install a component and/or provide an installation test (discussed
later). In this case, fixture 110 is designed to traverse on the
assembly station such that first aperture 122 of fixture 110
engages an aperture (shown later) of housing 101.
FIG. 1 further shows an enlarged view of fixture 110 having chamber
120. For purposes of clarity, some structures in the enlarged view
are removed. Chamber 120 is a cavity within fixture 110 extending
from one end inside fixture 110 to first aperture 122 located on
lateral surface 114 of fixture 110. In some embodiments, first
aperture 122 is a cylindrical shape. In the embodiment shown in
FIG. 1, first aperture 122 is generally rectangular. Generally,
first aperture 122 is designed to have an area larger than that of
an aperture of housing 101. This will be discussed later in detail.
Chamber 120 is generally of a dimension similar to that of first
aperture 122 throughout chamber 120. Also, chamber 120 is
configured to receive light sensor 130 used to align fixture 110
(and ultimately, the component) with the aperture of housing 101.
Light sensor 130 may be a photoelectric sensor, or any other device
configured to detect light from a light source external to housing
101 and determine the light intensity from the light source. As
shown in FIG. 1, light sensor 130 is attached to a top portion of
chamber 120. Fixture 110 further includes second aperture 124 on
top surface 116 of fixture, and cavity 126 extending from top
surface 116 of fixture 110 to an opening of chamber 120. Cavity 126
and second aperture 124 allow light sensor 130 to electrically
connect to a power source and/or an input module of a controller or
programmable unit (not shown) via conductive element 132. In other
embodiments, conductive element 132 may extend through a cavity
(not shown) to electrically connect with the power source,
controller, and/or programmable unit.
Also, fixture 110 includes pinhole 112 configured to receive column
170. Column 170 passes through fixture 110 and support member 171,
and is attached to a movable table (not shown) configured to move
in both a horizontal ("x") direction and vertical ("y") direction.
Column 170 and support member 171 may also be rotated by the
movable table around longitudinal axis 180 of column 170.
Accordingly, fixture 110 may also move in the same directions as
column 170 and support member 171. Advances in drilling techniques
allow for high precision in forming pinhole 112 such that when
column 170 engages fixture 110, fixture 110 is configured to have
relatively low tolerances. In other words, there is little unwanted
movement of fixture 110 with respect to column 170.
Release layer 146 is configured to detach from lateral surface 114
once the component is installed on housing 101. A first surface of
release layer 146 is attached to lateral surface 114 of fixture
110. A second surface (shown later) of release layer 146 may be
attached to the component to be installed on housing 101. Also,
when the component is installed, release layer 146 is further
configured to detach from the component.
FIGS. 2 and 3 illustrate the relationship of housing 101 and
component 140. FIG. 2 shows an exploded view of component 140
having first portion 141, mesh portion 143, and second portion 144.
First portion 141 includes recessed portion 142 and second portion
144 includes a recessed portion (not shown), both of which are
configured to receive mesh portion 143. Accordingly, some of the
dimensions of mesh portion 143 are less than that of first portion
141 and second portion 144. Also, first portion 141 further
includes aperture 151, second portion 144 includes aperture 154,
and release layer 146 includes aperture 156. Also, as shown in FIG.
2, aperture 151, aperture 154, and aperture 156 are generally of
the same dimensions. Also, although aperture 151, aperture 154, and
aperture 156 are generally rectangular, these apertures could
embody a different shape such that the apertures maintain
dimensions larger than that of aperture 103. Referring to FIG. 3,
aperture 151 includes length 157 and width 158. Aperture 103 of
housing 101, on the other hand, is smaller than that of aperture
151. In particular, aperture 103 includes length 105 and width 106
that are less than length 157 and width 158, respectively. This
allows aperture 103 to be positioned within aperture 151, or
conversely, for aperture 151 to extend around aperture 103 without
directly contacting aperture 103. The smaller cross sectional area
of aperture 103 as compared to the cross sectional area of aperture
151 allows a pressure sensitive adhesive ("PSA") (not shown) to be
applied to a surface of first portion 141 that faces housing 101
such that first portion 141 adhesively attaches to housing 101
without first portion 141 contacting any portion of aperture 103.
It should be noted this alignment is preferred in the assembly of
the device.
Referring again to FIG. 2, mesh portion 143 made of a generally
porous material. This allows light and/or sound waves to pass
through mesh portion 143. Despite the porous material, mesh portion
143 is configured to prevent certain contaminants (such as dust or
liquid) from entering the device. Also, mesh portion 143 may also
contribute to the acoustic performance of the device.
FIGS. 4-10 illustrate the alignment process for component 140 onto
housing 101. In FIG. 4, light source 190 directing light toward
aperture 103. In some embodiments, light source 190 is a laser. In
other embodiments, light source 190 could be an infrared light
source. Still, in other embodiments, light source 190 could be of a
particular color (such as visible red). These embodiments may be
useful in order to allow light sensor 130 to accurately detect
light from light source 190. In the embodiment shown in FIG. 4,
light source 190 is a collimated white light. In other words, the
white light emits several light rays, some of which are generally
parallel to each other. As shown in FIG. 4, only a portion of the
light from light source 190 may reach light sensor 130. The
alignment process is configured such that aperture 103 trims or
clips some of the light while allowing some of the light to pass
through aperture 103. For example, light ray 191 contacting housing
101 may be reflected by, or absorbed by, housing 101 but does not
pass through aperture 103. Light ray 192, however, passes through
aperture 103. Light passing through aperture 103 may also pass
through the aperture of component 140 (that is, the apertures of
the portions of component 140 as well as mesh portion 143) and
through the aperture of release layer 146. This light may be
detected by light sensor 130.
Light passing through aperture 103 may be having a higher intensity
in some portion as compared others. In other words, the light may
be brighter in some areas than in other areas. For example, FIG. 5
shows light gradient 210 taken along the line 5-5 in FIG. 4. In
some embodiments, the light source and the aperture are configured
to form light gradient 210 of several intensities. For example,
light gradient 210 may include first intensity 211, second
intensity 212, third intensity 213, fourth intensity 214, and fifth
intensity 215. The light intensity of light gradient 210 is highest
in the center of light gradient 210 than the outermost region. In
other words, first intensity 211 has a higher light intensity than
that of second intensity 212, and so on. Also, first intensity 211
may also be referred to as a local maximum of the light from light
source 190. Generally, first intensity 211 is at the center of the
light and also corresponds to the brightest component of the
light.
Light sensor 130 (shown in FIG. 4) is configured to detect all
intensities of light gradient 210. Also, light source 190 (shown in
FIG. 4) is aligned with aperture 103 such that first intensity 211
having light ray 195 extending through a central portion of
aperture 103. Accordingly, when light sensor 130 detects first
intensity 211, light sensor 130 and fixture 110 may be properly
aligned with housing 101 and/or aperture 103. Also, fixture 110
generally has low tolerance requirements not only in a rotational
direction, but also a vertical direction. For example, FIG. 4 shows
component having lip portion 10. Component 140 must be installed
without contacting lip portion 10. As such, it is critical to avoid
unwanted movement in the y-direction. Therefore, aligning fixture
110 with the local maximum of light gradient is important to ensure
that component 140 and/or fixture 110 do not contact lip portion 10
of housing 101.
FIGS. 6-9 illustrate fixture 110 traversing in a first direction
relative to light gradient 210 in order to align component 140 with
the aperture of the housing. In some embodiments, the first
direction is in the x-direction. In the embodiment shown in FIGS.
6-9, the first direction is the y-direction. Light sensor 130 may
be configured as an input device to a controller (not shown), such
as a programmable logic controller ("PLC"). Also, light sensor 130
may transmit current (on the order of milliamps) to signal the
light intensity read by light sensor 130. For example, a low
current transmitted by light sensor 130 corresponds to a low light
intensity, and a relatively higher current transmitted corresponds
to a higher light intensity. The controller may be configured to
read the light intensity readings from light sensor 130 (for
example, by converting current into a light intensity) and signal a
motor to drive a movable table (not shown), such as an X-Y table.
The controller may be proximate to fixture 110 or may be located in
another portion of the assembly process. Fixture 110, connected to
the movable table, may move fixture 110 in the x-direction and/or
the y-direction in order to properly align component 140 with an
aperture of the housing as previously described. In other
embodiments, light sensor 130 is coupled directly to a motor
configured to move a movable in response to current readings by
light sensor 130.
FIG. 6 shows light sensor 130 reading a light intensity
corresponding fourth intensity 214 of light gradient 210 (shown in
FIG. 5). In order to determine whether the portion of light
gradient 210 read by light sensor 130 is the highest intensity of
light gradient 210, the movable table actuates fixture 110 to
traverse along the y-direction to take further readings. As shown
in FIG. 7, light sensor 130 reads a light intensity corresponding
first intensity 211 of light gradient 210. While the controller may
determine first intensity 211 has a greater intensity than that of
fourth intensity 214, the movable table may further actuate fixture
110 to traverse along the y-direction to take further readings. As
shown in FIG. 8, light sensor 130 reads a light intensity
corresponding fourth intensity 214 of light gradient 210. At this
point, the controller may determine that fixture 110 is traversing
along the y-direction in a direction of decreasing light intensity,
and signal for the movable table to retract (or travel in the
opposite direction) to a position along the y-direction to the
position corresponding to the position in which light sensor 130
previously detected first intensity 211, as shown in FIG. 9. At
this point, the component 140 is aligned with the local maximum of
light intensity, and therefore, the aperture of the housing. A
similar process may be repeated in the x-direction in order to
further align component 140 with the local maximum. In other
embodiments, the alignment process may be programmed to run for a
predetermined period of time (for example, 1-5 seconds) and then
actuate fixture 110 to a position corresponding to the local
maximum, or highest light intensity, during the predetermined
period.
FIG. 10 is a flow chart 300 which details an alignment process. In
a first step 302, the light sensor takes an initial light intensity
reading to determine the light intensity of the light gradient at a
given location. The initial reading may be transmitted to a device
such as a controller. Then in step 304, the light source and the
fixture traverse along a first direction to take an additional
reading of the light gradient. The first direction could be the
x-direction or the y-direction. Then in step 306, the light sensor
takes another reading. In step 308, the controller may compare the
initial reading to the subsequent reading. If the subsequent
reading is higher than the initial reading, as shown in step 310,
the alignment process may be repeated beginning at step 306. If, on
the other hand, at step 308 it is determined that the subsequent
reading is less than the initial reading, then in step 312, the
light sensor and the fixture traverse in the opposite direction of
the first direction to a position corresponding the highest
intensity reading as determined by the light sensor. It should be
understood that the alignment process could include traversing in a
second direction that is substantially perpendicular to the first
direction. For example, the alignment process could traverse in the
x-direction if the process has traversed in the y-direction.
Contrary to the white light previously described, laser light is
generally a focused light source of a single light intensity.
Referring again to FIG. 4, in embodiments where light source 190 is
a laser light, light sensor 130 may generally act as a switch. In
other words, rather than detecting various light intensities, light
sensor 130 may switch to an "on" state when the laser light is
detected and switch to an "off" at all other light intensities (for
example, ambient light). As such, when laser light passes through
the central portion of aperture 103, the controller may signal for
fixture 110 to stop when light sensor 130 detects the laser light.
It should be understood that the cross section of the laser light
also generally represents the "local maximum" of the laser light
due to the characteristics of the laser light.
FIG. 11 illustrates a top view of showing release layer 146
attached to component 140 on a first surface of release layer 146,
and release layer 146 attached to fixture 110 on a second surface
of release layer. Also, fixture 110 includes length 118. Length 118
may be approximately in the range of 10 mm to 420 mm. Generally,
length 118 is such that when fixture 110 is rotated around column
170 in a direction toward housing 101, component 140 is
substantially parallel to housing 101 when component 140 is
proximate to housing 101. Also, as shown in FIG. 11, PSA 161 is
applied a surface first portion 141 of component 140. When
component 140 is properly aligned with aperture 103, the amount of
PSA 161 used to attach component 140 with housing 101 is such that
PSA 161 sufficient holds component 140 to housing 101 but does not
intrude into any portion of aperture 103.
Also, in some embodiments, several light sensors may be positioned
around the fixture. Each light sensor could transmit a light
intensity to a controller. The controller may use the readings from
the light sensors to calculate a local maximum of the light, and
actuate the fixture and component accordingly. Also, although not
shown, some embodiments may include a light sensor external with
respect to the housing of the device and a light within the housing
of the device. This may be advantageous where the light sensor
readings are critical and any movement of the light sensor is
undesirable.
Some embodiments may include a test in order to confirm the
component is properly attached to the housing. FIG. 12 illustrates
an acoustical test to determine whether the component is proper
installed on the housing. The acoustical test includes a microphone
410 on top surface 116 of fixture 110, generally above chamber 120.
The acoustical test also includes a speaker (shown later)
configured to emit sound into chamber 120 through an aperture of
housing 1001. In some embodiments, the acoustical test is performed
after the alignment process (previously described) and subsequent
installation of the acoustical seal.
FIG. 12 further shows housing 1001 including first alignment block
102 and second alignment block 104, both of which are configured to
guide fixture 110 such that the component is properly aligned with
housing 1001. Fixture 110 may slide along a surface of first
alignment block 102 and second alignment block 104. In some
embodiments, housing 1001 includes only a first alignment block
102. In other embodiments, housing 1001 includes three or more
alignment blocks. Still, in other embodiments, housing 1001 may not
have an alignment block (similar to housing 101 shown in FIG. 1).
First alignment block 102 and second alignment block 104 may serve
as a substitute to the alignment process previously described.
However, it should be understood that in some embodiments alignment
blocks may be used in conjunction with the alignment process. Also,
the acoustical test may be initiated by switch 422 on fixture 110.
Switch 422 may be electrically connected to microphone 410 and/or
the speaker. In some embodiments, switch 422 is electrically
connected to a controller (not shown). Also, switch 422 may be
further configured to set the PSA so the component may be
installed.
FIG. 13 illustrates a cross sectional view of a system for the
acoustical test which includes microphone 410 on fixture 110, audio
speaker 420 attached to an outer portion of housing 1001, and
switch 422. Housing 1001 includes first alignment block 102 to
ensure component 140 is aligned with aperture 103 before installing
component 140. Audio speaker 420 is attached to housing 1001 such
that audio speaker 420 transmits a test sound (shown as sound wave
425) in a direction through aperture 103, component 140, release
layer 146, and ultimately into chamber 120. As stated previously,
mesh portion 143 is made of material(s) which allow sound
transmission to permeate through mesh portion 143. Audio speaker
420 may be configured to transmit any sound from an audio
transmission device (not shown). Also, microphone 410 generally
detects sound transmissions from any source that emits sound. This
may include, for example, ambient noise in a device assembly plant.
Also, both microphone 410 and audio speaker 420 may be attached to
a controller (not shown) previously described.
It will be appreciated that release layer 146 is acoustically
sealed with fixture 110 a surface of release layer, and
acoustically sealed to component 140 on another surface of release
layer 146. In some embodiments (not shown), component 140 may be
directly attached to fixture 110 (that is, no release layer 146).
When component 140 is directly attached to fixture 110, component
140 is acoustically sealed with fixture 110.
FIG. 13 also shows interface region 430. Interface region 430 is a
portion in which component 140 engages housing 101, and extends
around an outer perimeter of component 140. Generally, interface
region 430 is a region most likely to emit sound transmission from
audio speaker 420 when component is not acoustically sealed with
housing 1001. To determine whether component 140 was properly
installed, audio speaker 420 emits a sound transmission ("test
sound"). If microphone 410 does not detect sound transmission from
audio speaker 420 through an interface region 430, component 140 is
acoustically sealed with housing 1001, and therefore properly
installed. However, if microphone 410 detects sound transmission
from audio speaker 420 through interface region 430, acoustical
seal 140 is not acoustically sealed with housing 101, and therefore
improperly installed on housing 101. In the latter event, the
controller may subsequently signal to another member of the
assembly line to remove housing 1001 having an improperly installed
component 140. As previously noted, this combined assembly and test
step occurs relatively early in the assembly process. Accordingly,
when a misaligned component 140 is detected, no further assembly to
housing 1001 is performed. This not only lowers cost associated
with installing additional components on a device that will
ultimately not be sold, but also allows another device to be
assembled in place of the device having a misaligned component
140.
In some embodiments, the controller may signal the audio
transmission device to transmit a sound through audio speaker 420
in a predetermined frequency range in which microphone 410 is
configured to receive. Accordingly, microphone 410 may ignore other
ambient noises not within the predetermined range. In other
embodiments, the acoustical test may include a second microphone
(not shown) configured to receive sound transmission from, for
example, ambient noise, allowing the acoustical test to "ignore"
ambient noise. For example, the controller may receive transmission
from microphone 410 and the second microphone, reduce each
transmission into a mathematical computation, and subtract sound
transmission of the second microphone from sound transmission from
microphone 410. The controller may then analyze the resultant sound
transmission to determine whether microphone 410 received sound
transmission from audio speaker 420.
For the acoustical test to perform properly, microphone 410 should
be capable of detecting sound transmission from audio speaker 420,
if at all, only through portions such as interface region 430. It
is essential, therefore, that audio speaker 420 be properly secured
to housing 101 such that sound transmission from audio speaker 420
passes only through aperture 103. Alternatively, it may be
necessary to acoustically block sound transmission from audio
speaker 420 passing over top portion 109 (shown in FIG. 13) of
housing 101. Also, although sounds wave 425 extend through chamber
120, sound wave 425 do not extend through cavity 126 in a manner
such that they may be detected by microphone 410. Further, fixture
110 is made of material(s) such that sound wave 425 generally do
not pass through fixture 110.
Installation issues (corresponding to a failure event) of component
140 may happen for several reasons. For example, FIG. 14
illustrates component 140 having a slanted surface 145. In other
words, slanted surface 145 is not substantially parallel with the
inner portion of housing 1001 where component 140 is generally
installed. This may be due to, for example, a manufacturing flaw of
component 140. Installation issues also include misalignment of a
properly manufactured component 140. In FIG. 15, for example,
component 140 is installed on housing 101 (shown also in FIG. 1) at
a portion lower than that of a properly aligned component 140. In
particular, a lower edge of component 140 is lower than aperture
103 of housing 101. In both cases, sound wave 425 may be permitted
to extend through interface region 430 and be detected by
microphone 410. Also, installation issue may also derive from
improperly setting PSA on, for example, the component 140. This may
create gaps between the PSA and component 140 thereby allowing
sound wave 425 to pass through interface region 430.
Other tests may be performed to ensure component 140 is properly
installed. For example, FIG. 16 illustrates a test system using
valve 450 connected to air line 460, and seal 470 configured to
plug aperture 103. In some embodiments, valve 450 is a pneumatic
valve. Also, in some embodiments, air line 460 may receive air
through an air compressor, or an air pump. In this test, air is
supplied to chamber 120 of fixture 110 through air line 460 and
valve 450. If air does not escape through interface region 430,
component 140 has been properly installed. However, if air escapes
through interface region 430, component 140 has been improperly
installed. Determining air escape may be performed by monitoring
pressure loss in chamber 120 or placing a structure near interface
region 430 configured to move when air from interface region 430
contacts the structure. Manual means for determine determining
proper installation of component 140 may also be performed. For
example, air passing through interface region 430 may make a sound
audible to an operator thereby indicating to the operator that
component 140 is improperly installed. These air tests described
herein may also be a combined assembly and test step performed
relatively early in the manufacturing process.
FIG. 17 illustrates a flow chart 600 for assembling and testing
installment of a component. In step 602, the component is aligned
with the aperture of the housing. Of course, this step is performed
before installing the component. Alignment may be performed by the
alignment process previously described (using at least a light and
at least a light sensor), and/or using alignment blocks on the
housing of the device. Then, in step 604, the component is
installed to the housing. This may performed, for example, by
rotating or swiveling a fixture (lever) around a longitudinal axis
of a column extending through the fixture. Then, in step 606, a
test is performed to determine if the component is properly
installed on the housing. Testing may include any test for
installment previously described (for example, the acoustical
test). If the test indicates the component is not properly
installed, in step 610, the housing is removed from the assembly
line. Then, in step 612, the discarded housing is replaced by a new
housing on the assembly line and the process is repeated at step
602. If, however, the test indicates the component is properly
installed, then in step 614, the housing is moved to the next step
of the assembly process. In step 616, the assembly process is
completed by installing the remaining components necessary to make
the device.
The foregoing description, for purposes of explanation, used
specific nomenclature to provide a thorough understanding of the
described embodiments. However, it will be apparent to one skilled
in the art that the specific details are not required in order to
practice the described embodiments. Thus, the foregoing
descriptions of the specific embodiments described herein are
presented for purposes of illustration and description. They are
not target to be exhaustive or to limit the embodiments to the
precise forms disclosed. It will be apparent to one of ordinary
skill in the art that many modifications and variations are
possible in view of the above teachings.
* * * * *